US4025489A - Utilization of bisphenol-A from the alkaline phase generated in the production of polycarbonates - Google Patents
Utilization of bisphenol-A from the alkaline phase generated in the production of polycarbonates Download PDFInfo
- Publication number
- US4025489A US4025489A US05/544,246 US54424675A US4025489A US 4025489 A US4025489 A US 4025489A US 54424675 A US54424675 A US 54424675A US 4025489 A US4025489 A US 4025489A
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- United States
- Prior art keywords
- solvent
- aqueous alkaline
- phosgene
- bpa
- solution
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- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 title claims abstract description 116
- 229920000515 polycarbonate Polymers 0.000 title claims abstract description 20
- 239000004417 polycarbonate Substances 0.000 title claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 229940106691 bisphenol a Drugs 0.000 title claims abstract description 10
- 239000002904 solvent Substances 0.000 claims abstract description 52
- YGYAWVDWMABLBF-UHFFFAOYSA-N Phosgene Chemical compound ClC(Cl)=O YGYAWVDWMABLBF-UHFFFAOYSA-N 0.000 claims abstract description 47
- 229920000642 polymer Polymers 0.000 claims abstract description 39
- 238000006243 chemical reaction Methods 0.000 claims abstract description 38
- 239000003054 catalyst Substances 0.000 claims description 39
- 239000000243 solution Substances 0.000 claims description 34
- ZMANZCXQSJIPKH-UHFFFAOYSA-N Triethylamine Chemical group CCN(CC)CC ZMANZCXQSJIPKH-UHFFFAOYSA-N 0.000 claims description 31
- 238000010517 secondary reaction Methods 0.000 claims description 29
- 229920005668 polycarbonate resin Polymers 0.000 claims description 17
- 239000004431 polycarbonate resin Substances 0.000 claims description 17
- 238000000034 method Methods 0.000 claims description 12
- AOGYCOYQMAVAFD-UHFFFAOYSA-N chlorocarbonic acid Chemical group OC(Cl)=O AOGYCOYQMAVAFD-UHFFFAOYSA-N 0.000 claims description 10
- 239000003960 organic solvent Substances 0.000 claims description 10
- 239000007788 liquid Substances 0.000 claims description 3
- 239000012429 reaction media Substances 0.000 claims description 3
- 239000012670 alkaline solution Substances 0.000 claims description 2
- 239000012071 phase Substances 0.000 description 30
- 238000011084 recovery Methods 0.000 description 16
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 15
- 230000000694 effects Effects 0.000 description 10
- 238000000926 separation method Methods 0.000 description 10
- 239000012046 mixed solvent Substances 0.000 description 8
- 238000005191 phase separation Methods 0.000 description 8
- 239000011541 reaction mixture Substances 0.000 description 8
- 239000000463 material Substances 0.000 description 6
- 235000011121 sodium hydroxide Nutrition 0.000 description 5
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 4
- 239000003518 caustics Substances 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- 229940083608 sodium hydroxide Drugs 0.000 description 4
- 239000002699 waste material Substances 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 3
- SJRJJKPEHAURKC-UHFFFAOYSA-N N-Methylmorpholine Chemical compound CN1CCOCC1 SJRJJKPEHAURKC-UHFFFAOYSA-N 0.000 description 3
- 239000002253 acid Substances 0.000 description 3
- 239000008346 aqueous phase Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- -1 i.e. Chemical compound 0.000 description 3
- HEDRZPFGACZZDS-UHFFFAOYSA-N Chloroform Chemical compound ClC(Cl)Cl HEDRZPFGACZZDS-UHFFFAOYSA-N 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- JUJWROOIHBZHMG-UHFFFAOYSA-N Pyridine Chemical compound C1=CC=NC=C1 JUJWROOIHBZHMG-UHFFFAOYSA-N 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 239000001273 butane Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- VLKZOEOYAKHREP-UHFFFAOYSA-N hexane Substances CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 2
- UAEPNZWRGJTJPN-UHFFFAOYSA-N methylcyclohexane Chemical compound CC1CCCCC1 UAEPNZWRGJTJPN-UHFFFAOYSA-N 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000006386 neutralization reaction Methods 0.000 description 2
- 239000011368 organic material Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 229910052708 sodium Inorganic materials 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 239000011780 sodium chloride Substances 0.000 description 2
- 239000007858 starting material Substances 0.000 description 2
- VZGDMQKNWNREIO-UHFFFAOYSA-N tetrachloromethane Chemical compound ClC(Cl)(Cl)Cl VZGDMQKNWNREIO-UHFFFAOYSA-N 0.000 description 2
- WGTYBPLFGIVFAS-UHFFFAOYSA-M tetramethylammonium hydroxide Chemical compound [OH-].C[N+](C)(C)C WGTYBPLFGIVFAS-UHFFFAOYSA-M 0.000 description 2
- GETQZCLCWQTVFV-UHFFFAOYSA-N trimethylamine Chemical compound CN(C)C GETQZCLCWQTVFV-UHFFFAOYSA-N 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- WSLDOOZREJYCGB-UHFFFAOYSA-N 1,2-Dichloroethane Chemical compound ClCCCl WSLDOOZREJYCGB-UHFFFAOYSA-N 0.000 description 1
- QAIGYXWRIHZZAA-UHFFFAOYSA-M 1-methylpyridin-1-ium;chloride Chemical compound [Cl-].C[N+]1=CC=CC=C1 QAIGYXWRIHZZAA-UHFFFAOYSA-M 0.000 description 1
- NGNBDVOYPDDBFK-UHFFFAOYSA-N 2-[2,4-di(pentan-2-yl)phenoxy]acetyl chloride Chemical compound CCCC(C)C1=CC=C(OCC(Cl)=O)C(C(C)CCC)=C1 NGNBDVOYPDDBFK-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- JLTDJTHDQAWBAV-UHFFFAOYSA-N N,N-dimethylaniline Chemical compound CN(C)C1=CC=CC=C1 JLTDJTHDQAWBAV-UHFFFAOYSA-N 0.000 description 1
- SVYKKECYCPFKGB-UHFFFAOYSA-N N,N-dimethylcyclohexylamine Chemical compound CN(C)C1CCCCC1 SVYKKECYCPFKGB-UHFFFAOYSA-N 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- CYTYCFOTNPOANT-UHFFFAOYSA-N Perchloroethylene Chemical group ClC(Cl)=C(Cl)Cl CYTYCFOTNPOANT-UHFFFAOYSA-N 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- XSTXAVWGXDQKEL-UHFFFAOYSA-N Trichloroethylene Chemical group ClC=C(Cl)Cl XSTXAVWGXDQKEL-UHFFFAOYSA-N 0.000 description 1
- 239000000370 acceptor Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- HTZCNXWZYVXIMZ-UHFFFAOYSA-M benzyl(triethyl)azanium;chloride Chemical compound [Cl-].CC[N+](CC)(CC)CC1=CC=CC=C1 HTZCNXWZYVXIMZ-UHFFFAOYSA-M 0.000 description 1
- KFSZGBHNIHLIAA-UHFFFAOYSA-M benzyl(trimethyl)azanium;fluoride Chemical compound [F-].C[N+](C)(C)CC1=CC=CC=C1 KFSZGBHNIHLIAA-UHFFFAOYSA-M 0.000 description 1
- QLRKASHXFNIPLZ-UHFFFAOYSA-M benzyl-dimethyl-phenylazanium;chloride Chemical compound [Cl-].C=1C=CC=CC=1[N+](C)(C)CC1=CC=CC=C1 QLRKASHXFNIPLZ-UHFFFAOYSA-M 0.000 description 1
- 239000004305 biphenyl Substances 0.000 description 1
- VCCBEIPGXKNHFW-UHFFFAOYSA-N biphenyl-4,4'-diol Chemical group C1=CC(O)=CC=C1C1=CC=C(O)C=C1 VCCBEIPGXKNHFW-UHFFFAOYSA-N 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-N carbonic acid Chemical compound OC(O)=O BVKZGUZCCUSVTD-UHFFFAOYSA-N 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 239000007809 chemical reaction catalyst Substances 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- MVPPADPHJFYWMZ-UHFFFAOYSA-N chlorobenzene Chemical compound ClC1=CC=CC=C1 MVPPADPHJFYWMZ-UHFFFAOYSA-N 0.000 description 1
- VGHOWOWLIXPTOA-UHFFFAOYSA-N cyclohexane;toluene Chemical compound C1CCCCC1.CC1=CC=CC=C1 VGHOWOWLIXPTOA-UHFFFAOYSA-N 0.000 description 1
- MMQWEMMTKXBCLU-UHFFFAOYSA-M cyclohexyl(trimethyl)azanium;bromide Chemical compound [Br-].C[N+](C)(C)C1CCCCC1 MMQWEMMTKXBCLU-UHFFFAOYSA-M 0.000 description 1
- GGSUCNLOZRCGPQ-UHFFFAOYSA-N diethylaniline Chemical compound CCN(CC)C1=CC=CC=C1 GGSUCNLOZRCGPQ-UHFFFAOYSA-N 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000004821 distillation Methods 0.000 description 1
- PGQAXGHQYGXVDC-UHFFFAOYSA-N dodecyl(dimethyl)azanium;chloride Chemical compound Cl.CCCCCCCCCCCCN(C)C PGQAXGHQYGXVDC-UHFFFAOYSA-N 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 150000003840 hydrochlorides Chemical class 0.000 description 1
- IXCSERBJSXMMFS-UHFFFAOYSA-N hydrogen chloride Substances Cl.Cl IXCSERBJSXMMFS-UHFFFAOYSA-N 0.000 description 1
- 229910000041 hydrogen chloride Inorganic materials 0.000 description 1
- 239000012433 hydrogen halide Substances 0.000 description 1
- 229910000039 hydrogen halide Inorganic materials 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 150000002576 ketones Chemical class 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- GYNNXHKOJHMOHS-UHFFFAOYSA-N methyl-cycloheptane Natural products CC1CCCCCC1 GYNNXHKOJHMOHS-UHFFFAOYSA-N 0.000 description 1
- 230000003472 neutralizing effect Effects 0.000 description 1
- 150000007530 organic bases Chemical group 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- 229920006254 polymer film Polymers 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- UMJSCPRVCHMLSP-UHFFFAOYSA-N pyridine Natural products COC1=CC=CN=C1 UMJSCPRVCHMLSP-UHFFFAOYSA-N 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 150000003839 salts Chemical group 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
- UBOXGVDOUJQMTN-UHFFFAOYSA-N trichloroethylene Natural products ClCC(Cl)Cl UBOXGVDOUJQMTN-UHFFFAOYSA-N 0.000 description 1
- OWGHQYPQNSZTFQ-UHFFFAOYSA-M triethyl(octadecyl)azanium;chloride Chemical compound [Cl-].CCCCCCCCCCCCCCCCCC[N+](CC)(CC)CC OWGHQYPQNSZTFQ-UHFFFAOYSA-M 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
- C08G64/40—Post-polymerisation treatment
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G64/00—Macromolecular compounds obtained by reactions forming a carbonic ester link in the main chain of the macromolecule
- C08G64/20—General preparatory processes
- C08G64/22—General preparatory processes using carbonyl halides
- C08G64/24—General preparatory processes using carbonyl halides and phenols
Definitions
- polycarbonate resins and methods for the preparation thereof are well-known to the art.
- polycarbonate resins are conventionally prepared by reacting an acid chloride of a carbonic acid with a diphenylolalkane in a heterogeneous liquid reaction medium comprising an aqueous alkaline solution containing a reaction catalyst and an inert organic solvent.
- the polycarbonate resin preferably comprises the reaction product of carbonyl chloride, i.e., phosgene, and 2,2-(4,4'-dihydroxydiphenyl)-propane, more commonly referred to as bisphenol-A, hereafter BPA, in a molar ratio of between about 1.1 to about 1.2 mols of phosgene per mol of BPA.
- BPA bisphenol-A
- diphenylolalkanes may also be used, such as, for example: (4,4'-dihydroxydiphenyl)-methane; 1,1-(4,4'-dihydroxy-diphenyl)-cyclohexane; 1,1-(4,4'-dihydroxy-3,3'-dimethyl-diphenyl)-cyclohexane; 2,2-(2,2'dihydroxy-4,4'-di-tert-butyl-diphenyl)-propane; 1,1-(2,2'-dihydroxy-4,4'-dimethyl-diphenyl)-butane; 3,4-(4,4'-dihydroxy-diphenyl)-hexane; 1,1-(4,4'-dihydroxy-diphenyl)-1-phenyl-ethane; 2,2'-(4,4'-dihydroxy-diphenyl)-butane; 2,2-(4,4'-dihydroxydiphenyl)-methane;
- the aqueous alkaline phase of the heterogeneous medium generally comprises aqueous solutions of water soluble alkaline materials or aqueous dispersions of water insoluble alkaline materials.
- inorganic alkaline materials which function as hydrogen halide acceptors.
- Exemplary of such materials are the oxides, hydroxides and carbonates of alkaline earth metals and alkali metals, such as, sodium, potassium, calcium, barium, strontium, magnesium and the like.
- a concentrated aqueous solution of sodium hydroxide is used having a sodium hydroxide content of from about 40 to about 60 percent by weight. Generally, about one mol of sodium hydroxide is used per mol of phosgene.
- the inert organic solvent is one in which the polycarbonate resin is soluble, sufficient solvent being used to produce about a 14 percent by weight solution of polycarbonate in the solvent.
- Typical of such solvents are methylene chloride, ethylene chloride; benzene; monochlorobenzene; methyl cyclohexane; cyclohexane; toluene; xylene; chloroform; carbon tetrachloride; trichloroethylene; perchloroethylene; and the like, as well as mixtures thereof.
- catalysts are trimethylamine; triethylamine; dimethylaniline; diethylaniline; dimethylcyclohexylamine; pyridine and the like, as well as the corresponding hydrochlorides.
- Suitable catalysts are tetramethylammonium hydroxide; triethyloctadecylammonium chloride; trimethylbenzylammonium fluoride; triethyl-benzylammonium chloride; dimethyldodecylammonium chloride; dimethylbenzylphenylammonium chloride; trimethylcyclohexylammonium bromide; N-methyl pyridinium chloride; N-methyl morpholine; and the like.
- a preferred catalyst is triethylamine and is used in amounts ranging from 0.1 to about 0.3 percent by weight based on the weight of polycarbonate and is preferably added after the initial reaction between the BPA and phosgene and prior to phase separation.
- the reaction between the BPA and phosgene occurs at the phase boundary or interface of the solvent/aqueous phases, the organic solvent retaining the polycarbonate resin thus formed in solution.
- the reaction medium is separated into two immiscible phases.
- the organic solvent phase containing the dissolved resin is further processed by conventional means such as, for example, distillation, non-solvent addition or the like to recover the resin and the aqueous alkaline phase is discharged to waste.
- the amount of BPA in the aqueous alkaline phase can vary between about 0.01 to about 0.7 percent by weight and is usually between about 0.1 to about 0.3 percent by weight with an average BPA content of about 0.25 percent by weight. It would be desirable if this BPA could be recovered and used in the production of additional polycarbonate, for in a full-scale operation, the amount of BPA contained in the alkaline layer is significant. For example, in a plant having a polycarbonate production capacity of about 60 million pounds per year, the excess BPA in the alkaline layer averages about 113 pounds per hour. Thus the recovery and utilization of this unreacted, excess BPA results in a two-fold advantage in that significant savings in the cost of starting materials will be realized and the organic materials content of the alkaline waste will be significantly reduced.
- an object of this invention to provide a means of recovering unreacted BPA from the aqueous alkaline phase generated in the production of polycarbonates. It is another object of this invention to provide a means of continuously recovering said BPA and returning the recovered BPA to the main reaction stream. A further object of this invention is to reduce the level of organic materials in the aqueous alkaline phase generated in the production of polycarbonates by recovering, in a usable form, a substantial portion of the unreacted BPA contained therein. An additional object of this invention is to provide a more efficient, more economical means of recovering unreacted BPA from the aqueous alkaline phase generated in the production of polycarbonate resin devoid of the disadvantages of the prior art.
- the invention comprises phosgenating the aqueous alkaline layer generated in the production of polycarbonate resin, the phosgene reacting with the unreacted BPA contained in the aqueous alkaline layer to produce a low molecular weight polymer having a high level of chlorocarbonate end groups and returning a solvent solution of the low molecular weight polymer to the main reaction stream.
- FIG. 1 is a flow sheet which depicts generally a typical polycarbonate production process embodying the invention.
- FIG. 2 is a graph showing the effect of phosgene/BPA molar ratio on BPA recovery from the aqueous alkaline phase.
- Polycarbonate starting materials are reacted in a primary reaction stage, the relative proportions of materials being selected in a manner well known to the art and described, for example, in U.S. Pat. Nos. 3,043,800; 3,046,255; 3,213,059; 3,173,891; 3,240,755 and 3,530,094.
- the reaction mixture is separated into two immiscible phases in a phase separation stage by means of a decanter or the like.
- the organic solvent phase containing the dissolved polycarbonate resin is drawn-off for further processing to recover and refine the finished resin.
- the aqueous alkaline phase containing unreacted BPA is conveyed to a secondary reaction stage to which is fed phosgene and solvent.
- the phosgene is dissolved in the solvent feed to the secondary reaction stage.
- the phosgene reacts with the unreacted BPA in the aqueous alkaline phase, the reaction occurring at the interface of the solvent/aqueous phases, to form a low molecular weight polymer having a high level of chlorocarbonate end groups due to the low level of BPA in the aqueous alkaline phase.
- the low molecular weight polymer is dissolved in the solvent and the solvent solution is separated in a phase separation stage and returned to the main reaction stream wherein an excess of BPA is present to completely react the chlorocarbonate end groups on the low molecular weight polymer.
- the catalyst being preferably added to the reaction mixture after the initial reaction in the primary reaction stage and prior to the introduction of the reaction mixture into the primary phase separation stage.
- the catalyst may be added between the secondary reaction stage and the secondary phase separation stage, the catalyst then being introduced into the main reaction stream along with the solvent solution of the low molecular weight polymer formed in the secondary reaction stage and recycled to the main stream.
- the addition of the catalyst between the secondary reaction stage and the secondary phase separation stage also enhances the reaction between the phosgene and unreacted, excess BPA in the aqueous alkaline layer resulting in increased removal of the unreacted BPA for a given set of reaction conditions.
- the amount of catalyst is based on the quantity of aqueous alkaline layer fed to the secondary reaction stage, about 0.02 percent by weight of catalyst being added based on the feed rate of aqueous alkaline layer. For example, assuming that 100 lb/hour of aqueous alkaline layer containing 0.25 percent by weight BPA is fed to the secondary reaction stage, 0.02 lb/hr. of, for example, triethylamine catalyst would be used, resulting in a molar ratio of catalyst to BPA of about 0.22 to 1. It is surprising that the low molecular weight polymer would be formed in the presence of such a relatively large amount of catalyst since it is well known that using excessive amounts of catalyst could hinder rather than promote a chemical reaction.
- the BPA content in the alkaline aqueous layer may be reduced to less than 0.01 percent by weight, in which case a molar ratio of at least about 2.5 mols of phosgene per mol of BPA has proved to be optimum.
- sufficient solvent be used to produce less than 5.0 percent and preferably about a 2.5 percent by weight solution of low molecular weight polymer in the solvent. If less solvent is used, for example, only sufficient solvent to produce about a 5.0 percent by weight polymer solution, BPA recovery is retarded.
- the extent of BPA recovery is also a function of residence time in the secondary reaction stage, the more time allowed for reaction, the more BPA is converted to the low molecular weight polymer.
- the residence time in the reactor should not, as a practical matter, exceed about 5 or 6 minutes and preferably not more than about 2 minutes.
- a polycarbonate resin is prepared in a conventional manner by reacting in a primary reaction stage about 1.1 to about 1.2 mols of phosgene per mol of BPA in a heterogeneous liquid medium comprising an aqueous caustic solution and a mixed organic solvent.
- the aqueous caustic solution contains about 40 to 60 percent by weight sodiumhydroxide and is used in such quantity so that about 1 mol of NaOH is present for each mol of phosgene.
- Sufficient mixed solvent is used so as to produce an about 14 percent by weight solution of polycarbonate in the mixed solvent.
- the residence time in the primary reaction stage is about 2 to 5 minutes after which the reaction mixture is charged to a primary separation stage.
- a typical aqueous alkaline phase generated in the production of a polycarbonate resin according to Example 1 has the following analysis:
- the aqueous alkaline phase is fed to the secondary reaction stage at a rate of about 744 lbs/hr, which corresponds to about 0.0091 lb-mols/hr of BPA.
- about 0.02275 lbs-mols/hr of phosgene dissolved in a mixed solvent is fed to the secondary reaction stage, sufficient mixed solvent being used such that the low molecular weight polymer resulting from the reaction of phosgene and BPA will form about a 2.5 percent by weight solvent solution.
- the molar ratio of phosgene to BPA is about 2.5 to 1 and the residence time in the secondary reaction stage is about 2 minutes.
- reaction mixture is then fed to the secondary separation stage to effect phase separation, the residence time in the secondary phase separation stage being about 2 minutes.
- the solvent phase containing the dissolved low molecular weight polymer is returned to the main reaction stream and the aqueous alkaline phase is discharged to waste.
- the polymer produced has a low molecular weight and contains a high level of chlorocarbonate end groups, therefore, it is readily reacted in the main reaction stream as the excess of BPA in the main stream will completely react the chlorocarbonate end groups.
- the quantity of solvent used in the secondary reaction stage is a factor in optimizing the extent of recovery of BPA from the aqueous alkaline layer and sufficient solvent should be used to provide a solution of low molecular weight polymer of less than 5 percent by weight and preferably about 2.5 percent by weight.
- a catalyst can be added either between the primary reaction stage and the primary separation stage or between the secondary reaction stage and the secondary separation stage.
- the catalyst In the former case, between about 0.06 and 0.40 percent by weight of catalyst is used based on the weight of polycarbonate resin and in the latter case, about 0.02 percent by weight of catalyst is used based on the weight of aqueous alkaline layer, and the catalyst enters the main reaction stream along with the solvent solution of the low molecular weight polymer.
- the catalyst to BPA molar ratio is quite high and it is surprising that BPA recovery is enhanced as it is known that an excessive amount of catalyst could inhibit rather than accelerate a chemical reaction.
- the optimum molar ratio of phosgene to BPA in the aqueous alkaline layer is about 2.5 to 1.
- a low phosgene/BPA ratio results in less efficient BPA removal while BPA removal is not significantly improved at phosgene/BPA molar ratios much in excess of 2.5 to 1.
- the use of excessive amounts of phosgene are to be avoided as the same increases the acidity of the aqueous alkaline layer and could cause problems in the waste treatment facility in which the aqueous alkaline layer is treated subsequent to BPA removal and prior to discharge from the plant.
- the invention provides a relatively simple and straight-forward means of removing excess, unreacted BPA from the aqueous alkaline phase generated in the production of polycarbonates.
- the examples further illustrate that the extent of BPA removal is enhanced by a number of factors, notably the amount of solvent fed to the secondary reaction stage, the addition of a catalyst in the BPA removal stage and the molar ratio of phosgene to BPA in the aqueous alkaline phase.
Landscapes
- Chemical & Material Sciences (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Polyesters Or Polycarbonates (AREA)
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US05/544,246 US4025489A (en) | 1975-01-27 | 1975-01-27 | Utilization of bisphenol-A from the alkaline phase generated in the production of polycarbonates |
CA242,479A CA1049565A (en) | 1975-01-27 | 1975-12-23 | Separation of bisphenol-a from the alkaline phase generated in the production of polycarbonates |
DE19762602366 DE2602366A1 (de) | 1975-01-27 | 1976-01-22 | Rueckgewinnung von diphenylolalkanen aus der bei der herstellung von polycarbonaten entstehenden alkalischen phase |
JP51006040A JPS5930726B2 (ja) | 1975-01-27 | 1976-01-23 | ポリカ−ボネ−ト樹脂の製造方法 |
NLAANVRAGE7600775,A NL181202C (nl) | 1975-01-27 | 1976-01-26 | Continue werkwijze voor de bereiding van macromoleculaire polycarbonaten. |
FR7602152A FR2298568A1 (fr) | 1975-01-27 | 1976-01-27 | Procede po |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US05/544,246 US4025489A (en) | 1975-01-27 | 1975-01-27 | Utilization of bisphenol-A from the alkaline phase generated in the production of polycarbonates |
Publications (1)
Publication Number | Publication Date |
---|---|
US4025489A true US4025489A (en) | 1977-05-24 |
Family
ID=24171385
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US05/544,246 Expired - Lifetime US4025489A (en) | 1975-01-27 | 1975-01-27 | Utilization of bisphenol-A from the alkaline phase generated in the production of polycarbonates |
Country Status (6)
Country | Link |
---|---|
US (1) | US4025489A (enrdf_load_stackoverflow) |
JP (1) | JPS5930726B2 (enrdf_load_stackoverflow) |
CA (1) | CA1049565A (enrdf_load_stackoverflow) |
DE (1) | DE2602366A1 (enrdf_load_stackoverflow) |
FR (1) | FR2298568A1 (enrdf_load_stackoverflow) |
NL (1) | NL181202C (enrdf_load_stackoverflow) |
Cited By (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4346210A (en) * | 1977-08-09 | 1982-08-24 | Bayer Aktiengesellschaft | Process for the preparation of polycarbonates catalyzed by cyclic aza compounds |
US4367330A (en) * | 1979-09-20 | 1983-01-04 | Bayer Aktiengesellschaft | Process for the preparation of aromatic polycarbonates by the phase boundary process |
US4638077A (en) * | 1984-11-29 | 1987-01-20 | General Electric Company | Method for the preparation of chloroformate compositions |
US4649210A (en) * | 1985-09-23 | 1987-03-10 | General Electric Company | Reducing phosgenation reaction temperatures |
US4737573A (en) * | 1986-10-10 | 1988-04-12 | General Electric Company | Method for polymerizing aromatic bischloroformate composition to polycarbonate |
US5317043A (en) * | 1990-07-27 | 1994-05-31 | Belland Ag | Process for the recovery of polymers dissolvable in aqueous alkaline or acid media |
US5376741A (en) * | 1992-11-20 | 1994-12-27 | Bayer Aktiengesellschaft | Process for the preparation of polycarbonates |
US5508375A (en) * | 1992-12-10 | 1996-04-16 | Bayer Aktiengesellschaft | Process for the preparation of polycarbonates |
USRE35499E (en) * | 1988-11-16 | 1997-04-29 | The Dow Chemical Company | Elimination of monocarbonate from polycarbonate |
CN1037688C (zh) * | 1992-12-10 | 1998-03-11 | 拜尔公司 | 聚碳酸酯的制备方法 |
US5876851A (en) * | 1993-05-19 | 1999-03-02 | Teijin Limited | Film from polycarbonate, polyester to be laminated on metal |
US6420517B1 (en) * | 2001-02-06 | 2002-07-16 | General Electric Company | Process for resin phase separation by plate decantation |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3028365A (en) * | 1953-10-16 | 1962-04-03 | Bayer Ag | Thermoplastic aromatic polycarbonates and their manufacture |
US3046255A (en) * | 1957-06-20 | 1962-07-24 | Pittsburgh Plate Glass Co | Process for preparing polycarbonates |
US3437639A (en) * | 1965-09-10 | 1969-04-08 | Eastman Kodak Co | Process for purifying polycarbonates |
US3646102A (en) * | 1968-08-28 | 1972-02-29 | Idemitsu Kosan Co | Method for continuously preparing polycarbonate oligomer |
US3787359A (en) * | 1971-01-15 | 1974-01-22 | Basf Ag | Continuous manufacture of high molec-ular weight linear polycarbonates |
Family Cites Families (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3240755A (en) * | 1960-12-29 | 1966-03-15 | Allied Chem | Process for the preparation of polycarbonates |
-
1975
- 1975-01-27 US US05/544,246 patent/US4025489A/en not_active Expired - Lifetime
- 1975-12-23 CA CA242,479A patent/CA1049565A/en not_active Expired
-
1976
- 1976-01-22 DE DE19762602366 patent/DE2602366A1/de active Granted
- 1976-01-23 JP JP51006040A patent/JPS5930726B2/ja not_active Expired
- 1976-01-26 NL NLAANVRAGE7600775,A patent/NL181202C/xx not_active IP Right Cessation
- 1976-01-27 FR FR7602152A patent/FR2298568A1/fr active Granted
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3028365A (en) * | 1953-10-16 | 1962-04-03 | Bayer Ag | Thermoplastic aromatic polycarbonates and their manufacture |
US3046255A (en) * | 1957-06-20 | 1962-07-24 | Pittsburgh Plate Glass Co | Process for preparing polycarbonates |
US3437639A (en) * | 1965-09-10 | 1969-04-08 | Eastman Kodak Co | Process for purifying polycarbonates |
US3646102A (en) * | 1968-08-28 | 1972-02-29 | Idemitsu Kosan Co | Method for continuously preparing polycarbonate oligomer |
US3787359A (en) * | 1971-01-15 | 1974-01-22 | Basf Ag | Continuous manufacture of high molec-ular weight linear polycarbonates |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4346210A (en) * | 1977-08-09 | 1982-08-24 | Bayer Aktiengesellschaft | Process for the preparation of polycarbonates catalyzed by cyclic aza compounds |
US4367330A (en) * | 1979-09-20 | 1983-01-04 | Bayer Aktiengesellschaft | Process for the preparation of aromatic polycarbonates by the phase boundary process |
US4638077A (en) * | 1984-11-29 | 1987-01-20 | General Electric Company | Method for the preparation of chloroformate compositions |
US4649210A (en) * | 1985-09-23 | 1987-03-10 | General Electric Company | Reducing phosgenation reaction temperatures |
US4737573A (en) * | 1986-10-10 | 1988-04-12 | General Electric Company | Method for polymerizing aromatic bischloroformate composition to polycarbonate |
USRE35499E (en) * | 1988-11-16 | 1997-04-29 | The Dow Chemical Company | Elimination of monocarbonate from polycarbonate |
US5317043A (en) * | 1990-07-27 | 1994-05-31 | Belland Ag | Process for the recovery of polymers dissolvable in aqueous alkaline or acid media |
US5376741A (en) * | 1992-11-20 | 1994-12-27 | Bayer Aktiengesellschaft | Process for the preparation of polycarbonates |
CN1037445C (zh) * | 1992-11-20 | 1998-02-18 | 拜尔公司 | 聚碳酸酯的制备工艺 |
US5508375A (en) * | 1992-12-10 | 1996-04-16 | Bayer Aktiengesellschaft | Process for the preparation of polycarbonates |
CN1037688C (zh) * | 1992-12-10 | 1998-03-11 | 拜尔公司 | 聚碳酸酯的制备方法 |
US5876851A (en) * | 1993-05-19 | 1999-03-02 | Teijin Limited | Film from polycarbonate, polyester to be laminated on metal |
US6420517B1 (en) * | 2001-02-06 | 2002-07-16 | General Electric Company | Process for resin phase separation by plate decantation |
Also Published As
Publication number | Publication date |
---|---|
FR2298568B1 (enrdf_load_stackoverflow) | 1979-08-24 |
DE2602366C2 (enrdf_load_stackoverflow) | 1988-02-25 |
DE2602366A1 (de) | 1976-07-29 |
FR2298568A1 (fr) | 1976-08-20 |
NL181202B (nl) | 1987-02-02 |
NL7600775A (nl) | 1976-07-29 |
NL181202C (nl) | 1987-07-01 |
JPS5930726B2 (ja) | 1984-07-28 |
JPS51100191A (enrdf_load_stackoverflow) | 1976-09-03 |
CA1049565A (en) | 1979-02-27 |
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